Fuel Pump Problems of Ford F-150 - part 1

Fuel Pump problem of the 2001 Ford F-150
1

Failure Date: 05/19/2014

The contact owns a 2001 Ford F-150. The contact stated that while driving approximately 15 mph, the fuel tank became detached from under the vehicle. The vehicle was towed to an independent mechanic, who replaced the fuel tank and the fuel pump. The manufacturer was not notified of the failure. The approximate failure mileage was 172,000.

Fuel Pump problem of the 2006 Ford F-150
2

Failure Date: 01/22/2014

Went to start truck and engine would crank but would not fire. I tried the starting fluid test to see if it was an ignition problem or fuel problem. Gave a little shot of starting fluid into the intake and then tried to start. Motor acted like it was going to start but never started beings I didn't give it enough starting fluid to start because I'm not a fan of using it. With that I eliminated the ignition had to be fuel. I got on the internet and searched no start problem for 2006 F-150 and found a you tube video of the fuel pump control module rusting out. Went out and dropped spare tire and took the control module off the cross member and noticed the hole corroded through the housing just like the video. I got the upgraded part from a Ford dealer for $163 and installed. Runs fine now. My biggest complaint is Ford knows there's a problem since the have came out with an upgraded control module so why isn't this a recall? I live in a state that temperatures in the winter months can be below 0 degrees fahrenheit and drive an hour one way to work, this could have happened when I was on the road in extreme cold, could of had my two children with me broke down on the side of the road and cold out. Luckily it happened at home but still it was 4 degrees out and laying under my truck taking the module off was not very pleasant. Think this is something that Ford needs to do something about.

Fuel Pump problem of the 2005 Ford F-150
4

Failure Date: 01/18/2014

Truck started stalling in traffic & intersections. Had to continue to restart. Finally made it home. Then took it in for repair. Remove & replace fuel pump control module (part was severely corroded) technician was surprised that the truck even ran. Ford pick a poor location for such an important part of the fuel delivery system. Should have been a recall item. Repair cost me $413. 08.

Fuel Pump problem of the 2009 Ford F-150
5

Fuel Pump problem of the 2004 Ford F-150
6

Failure Date: 01/08/2014

Fuel pump driver module, back side of module corroded away exposing circuit board causing the fuel pump to stop running and leaving me stranded during a snow storm,seems to be a common problem on 2004-2008 Ford pickups. I consider this a poor design and should be a recall, lot of garages installing new fuel pumps at 300. 00 a crack when its a easy to replace 80. 00 dollar part.

Fuel Pump problem of the 2007 Ford F-150
7

Failure Date: 01/06/2014

I was accelerating from a stop and vehicle shut off. I am 8mths pregnant and was stuck on the side of the road for over a 1/2 hour in -45 degree weather waiting for tow truck, because vehicle would not start. Mechanic looked at vehicle and found #9 fuse for fuel pump blown. Fuse replaced, and vehicle ran for 30seconds and electrical plug to driver control module began to smoke and melt. Driver control module and electrical plug replaced, and vehicle runs. I would have like to have been notified by Ford to avoid my stranded experience in -45 degree weather. This was a huge safety risk and it can be avoided. Ford should have located this device near the fuse box or under hood by fire wall plenty of room and same amount of wire.

Fuel Pump problem of the 2006 Ford F-150
8

Failure Date: 08/05/2013

My 2006 Ford f150 fx4 has stalled on the highway at two different times in the last 9,000 miles. I am driving at normal speeds, with normal weather conditions, half tank of gas, and I was coasting as highway speeds slowed - as I went to hit the accelerator to speed up, I lost the ability to accelerate. First the wrench dash light came on, then I noticed steering was slightly difficult and then the battery and transmission light came on. I got the vehicle to the side of the road, but I did not lose headlights, radio, heat, or power. I turned the truck off and waited 2 minutes, then it started back up - a little difficult on the starter, but it worked. I have read numerous chat forums online with users having this same issue with 2006 v8's in the f150. What is Ford doing about this? my vehicle has been meticulously maintained and cared for. From what I read this is a fuel pump control panel issue with corrosion of dissimilar metals - where is the recall?.

Fuel Pump problem of the 2007 Ford F-150
9

Failure Date: 08/23/2012

Fuel pump control module failure resulting in engine stalling causing loss of power and control to steering and braking functions at high speed and in heavy traffic. The fuel pump control module on the truck failed at intermittent and erratic intervals, causing immediate shut off of fuel to the engine. Control functions, particularly power steering were compromised and accidents were barely avoided. The engine would eventually restart- up to the point that the module failed completely. The first fuel pump control module was replaced around 14000 miles in 2010. The second was just replaced at 24446 miles. The cost to replace the fuel pump control module is approximately $500.

Fuel Pump problem of the 2009 Ford F-150
10

Failure Date: 04/02/2012

First, the fuel door fell off the truck. Later that evening I heard a weird suction sound coming from the fuel door area. It began to idle rough, then would not want to start after fill ups. When you would stick the gas nozzle in the tank a loud "whoosh" sound would emit as it relieved pressure. My gas gauge stopped functioning and all of these issues eventually leading to the tank imploding/collapsing on itself. This bent the fuel pump and gas gauge inside the tank. I paid out of pocket to have it fixed because the Ford dealership told me the warranty only "covered moving parts". I asked if the fuel gauge float and fuel pump moved. They enjoyed my rhetoric, but declined to fix the problem. They only replaced a sensor that threw a lean bank one code and caused the check engine light to come on. I drove it for the next year or so using the odometer to tell me when to fill up as my gas gauge no longer worked. . Fast forward a year and a half, and running out of gas 3 or 4 times, and it has done the same thing to me again. I just paid $972. 19 to a private garage to replace the fuel pump, but I only got a 90 day warranty on the work and no guarantee that this issue will not happen again. When I googled the make and model of the truck I found all kinds of information about people having the same problem, yet Ford acted like they have never heard of this before. I understand I am responsible for keeping the truck running, but nothing about the way I operate the vehicle made it do this. If I get in a wreck, I should pay to fix it. This is a design flaw and should be recalled. Btw I was doing 70 mph on the interstate when it shut down most recently and traffic had me boxed in. It nearly caused a collision just getting it off the road. Had I died, no one would have questioned what caused the accident.

Fuel Pump problem of the 2005 Ford F-150
11

Failure Date: 02/16/2012

My fuel pump module shorted out. It had become corroded. There was a melting of plastic parts in the module. I could smell the plastic burning before the unit failed. The truck was running fine and then suddenly died when the module failed. Fortunately, I was driving through a small town when this happened. If it would have happened on the highway it could have been a very dangerous situation. I feel Ford should be performing a recall on these modules. It's a very poor design. I also feel that the truck owners should be compensated for the repairs that have already been done.

Fuel Pump problem of the 2006 Ford F-150
12

Failure Date: 02/05/2012

There is a fuel drive module and controls the electrical output to the fuel pump. Oem part number fl8a-9d370-aa. The module is mounted to the one of the rear frame crossbars, above the spare tire on the f150 pickups. Due to the placement and mounting salt and road debris get stuck between module and frame and cause massive eroding of the metal housing causing the module to fail. My trucks module failed at around 44,000 miles.

Fuel Pump problem of the 2007 Ford F-150
13

Failure Date: 02/05/2012

While driving truck it shut off suddenly without and warning, driver fuel pump control module. This unit is located in an area that is highly corrosive and has no protection against the elements. When this part failed I was driving in a parking lot at a low speed however I was told it can happen any time at all. Once this part goes the vehicle is totally inop. I had to have the truck towed in to the dealer and the part replaced at a cost of $356. 00 labor $125. 00 parts. I was also told I was lucky it took this long and had better plan on doing it again in the near future as it is a common issue with all Ford trucks. Ford redesigned the part but the service manager told me it will happen again as it is only nickel coated and offers no protection from the elements.

Fuel Pump problem of the 2005 Ford F-150
14

Failure Date: 02/02/2012

My 2005 F-150 truck stalled right in front of my house just outside of my driveway, my neighbor and I had to push it in as to not block my street. Luckily it didn't die out on the highway which I was on five minutes before it died out. I was thinking the fuel pump went, but with only 68,000 miles that would not be very good. After some research on the net this little part named fuel pump drive module gets my attention. I took down the spare tire took out the two bolts that hold the fpdm in and wow this part was corroded with a hole in it and a crack!!! so after $144. 00 for part # 4l3z-9d370-a from Ford dealer and about 45 minutes of my time, I'm rolling again, lucky for me no tow fees just a few beers for my neighbor. What a joke that Ford can allow this bad design to continue and not be rectified by recalling all the vehicles this was installed on. I guess that wont happen till a few people lose there lives because of it.

Fuel Pump problem of the 2006 Ford F-150
15

Failure Date: 02/01/2012

Truck does not start
fuel pump does not run . Remove spare tire for access and found fuel pump driver module broken and corroded. Should be a recall!!!.

Fuel Pump problem of the 2004 Ford F-150
16

Failure Date: 01/24/2012

The contact owns a 2004 Ford F-150 extended cab. The contact stated after cleaning the vehicle, it failed to start. A private mechanic confirmed that water entered an exposed module for the fuel pump and needed to be replaced. The manufacturer was not notified of the failure. The vehicle was repaired. The failure and current mileage was 153,000.

Fuel Pump problem of the 2004 Ford F-150
17

Failure Date: 10/03/2011

The contact owns a 2004 Ford f150. The contact stated that while driving 45 mph, the vehicle stalled without warning. The vehicle was towed to the dealer where it was diagnosed with a faulty fuel pump driver module. The dealer performed the repairs. The manufacturer was aware of the failure. The current and failure mileages were 61,552. Updated 11/03/11.

Fuel Pump problem of the 2009 Ford F-150
18

Failure Date: 07/20/2011

**catastrophic fuel tank failure** two days ago my 2009 f150 died in my driveway, it acted as if out of fuel even though the gage read over half a tank. I had it towed to a Ford dealer and was initially informed that the truck was out of gas and the fuel gage wasn't working. A new unit was ordered and once the tank was removed from the truck it was discovered that the issue was exceedingly more severe. The mechanic and a Ford engineer concluded that the charcoal purge valve failed and the fuel pump created such a strong vacuum that the fuel tank collapsed on itself and crushed the fuel pump. Although the truck has only 15,000 miles it is not a warranty repair due to a salvage title on the vehicle. After the inspection it was concluded that the fuel tank unit was not damage or effected by any incident and was in standard operating condition when the event occurred. I also understand that since this is not a warranty repair, Ford will not be collecting the parts for further evaluation. I believe this to be a mistake! I have asked to keep these parts and will provide them to Ford if need be. As an engineer I believe this to be a design flaw that could present a severe safety hazard.

Fuel Pump problem of the 2004 Ford F-150
19

Failure Date: 07/13/2011

The contact owns 2004 Ford F-150. The contact stated that the vehicle would not start. The vehicle was taken to an independent mechanic where the contact was informed that the fuel pump and fuel module failed. Both the fuel pump and module were replaced. The manufacturer was made aware of the failure and advised the contact to notify NHTSA. The failure and current mileages were 58,715.

Fuel Pump problem of the 2006 Ford F-150
20

Failure Date: 05/14/2011

Driving on interstate 90 in michigan truck started misfiring and about 1000 feet later the engine quit altogether. Replaced the fuel pump module which the mechanic said was very common in northern states. Corrosion between disimilar metals caused the module case to break and allow water inside and short the module out.

Fuel Pump problem of the 2004 Ford F-150
21

Failure Date: 05/01/2011

Tl-the contact owns a 2004 Ford F-150. The contact stated the vehicle would not start. The vehicle was towed to an independent repair shop where the contact was informed the fuel pump driver module failed due to corrosion. The manufacturer was notified and the contact was informed the parts necessary to remedy the failure were unavailable. The contact also stated the same failure occurred approximately 30,000 miles prior. The vehicle was not repaired. The failure and current mileages were 150,000. Sm.

Fuel Pump problem of the 2004 Ford F-150
22

Failure Date: 04/23/2011

I went to start the vehicle, hand slipped off of the key, the vehicle would crank but not turn over. Tried to restart the vehicle numerous times. Unplugged the battery, left it sit for 10-15 mins (thought it was the anti theft). Later in the day a friend looked at it, troubleshot it as fuel pump- used owner manual to look at fuses, everything looked fine. Concluded had to be with the fuel pump or sensor. Had to have the vehicle towed to a garage, pulled the fuel pump sensor off, there was a giant whole in the outer layer and plastic was cracked. Moisture fried the circuit board. The part is currently at vrtc. I am glad my vehicle was at home and not somewhere in a parking lot or far from home. No real signs of this happening prior to not starting.

Fuel Pump problem of the 2005 Ford F-150
23

Failure Date: 04/20/2011

We have a 2005 F-150 Ford pickup. Latter part of April 2011 I was coming home from work the truck just shuts off. Will not restart. Have it towed to the garage they scanned it and said the fuel pump and the fuel module needed replaced. Order the parts through Ford motor company , can't get them anywhere else. Didn't receive them called again and put a rush on them may 5th, 2011. Never recieved parts until in June 2011. We called several times to find out why it was taking so long and was told they were on back order. When we finally recieved them they said there was 1600 shipped out and 4300 on back order. Done some checking and found out that there were many, many more people with the same problem. Ater getting the parts and having them installed now the check engine light comes on the garage scans it and now in needs a fuel tank pressure sensor and guess what nobody has one. I need this vehicle for my job and besides that this is getting very costly. I feel Ford motor company should be taking care of this problem and reimbursing those who have spent all this money on this problem. After all four months is way to long to wait on parts to solve a problem especially when you have to get the parts from them.

Fuel Pump problem of the 2005 Ford F-150
24

Failure Date: 03/20/2011

Fuel pump control module is subject to corrosion due to location. I was driving up hill on the freeway when my 2005 f150 stalled. I lost all power, power steering, brakes. I was nearly killed when the semi behind me could not stop in time due to the failure of fuel pump control module. Thankfully I was strong enough to force the truck to the shoulder and stop despite having no power brakes or steering while towing a 6000 lb trailer. After paying for a tow for my truck and trailer I find hundreds of reports dealing with the faulty placement of the fuel pump control module online. At the repair shop I was amazed by the extent of the corrosion. There was barely anything left of the module. The part was replaced with the same faulty controler due to a backorder from Ford because the problem is so wide spread. I almost died due to a known problem that should have never been allowed to occur.

Fuel Pump problem of the 2004 Ford F-150
25

Failure Date: 03/18/2011

My 2004 Ford F-150 died in the exit to a local plaza blocking traffic from exiting. After about a half an hour I got the truck started and drove to the Ford service dept. I was told the fuel pump driver module has corroded through and that this part was on national back order because of the number of failures due to the poor location of the module. I was fortunate to find the last replacement part in the western NY area but since have talked to other's all over then country trying to get the same part with no luck. The fact that tis part is on national back order should be proof enough that this is a serious problem. I was charged $375 ($160 for part and $200 for labour for a 15 minute job). I believe this could pose a serious safty hazard if a vehicle fails in the wrong place.